Code No: RT41039 R13 Set No.

1
IV B.Tech I Semester Regular/Supplementary Examinations, October/November - 2017
AUTOMATION IN MANUFACTURING
(Mechanical Engineering)
Time: 3 hours Max. Marks: 70
Question paper consists of Part-A and Part-B
Answer ALL sub questions from Part-A
Answer any THREE questions from Part-B
*****
PART–A (22 Marks)
1. a) List the merits and demerits of the automations in production systems. [4]
b) In a 10-station transfer line, the probability that a station breakdown will occur
for a given work part is equal to 0.01. This probability is the same for all 10
stations. Determine the frequency of line stops per cycle on this flow line using
the upper-bound approach. [3]
c) Define (i) Minimum rotational work elements (ii) precedence constraints. [4]
d) What are the technologies used for vehicle guidance in AGVs [4]
e) What is meant by adaptive control constraint (ACC). [4]
f) Define Inspection. [3]

PART–B (3x16 = 48 Marks)

2. a) Explain ten strategies for automation and process improvement [8]
b) Write about fixed automation and programmable automation. [8]

3. a) A 2 station transfer line has an ideal cycle time of Tc = 1.2 mins. The
probability of station breakdown per cycle is equal for all stations & P =0.005
breakdowns / cycle. For each of the upper bound & lower bound determine: i)
frequency of line stops per cycle ii) average actual production rate iii) line
efficiency [8]
b) Explain any four reasons, why storage buffers are used on automated
production lines? [8]

4 A manual assembly line is to be designed to make a small consumer product. The work
elements, their times, and the precedence constraints are as follows :
Preceded Preceded
Element Time (min) Element Time (min)
by: by :
2 0.7 1 7 0.3 4
3 0.5 1 8 0.9 4,9
4 0.8 2 9 0.3 5,6
5 1.0 2,3 10 0.5 7,8
The workers will operate the line for 400 min per day and must produce 300
products per day. A mechanized belt, moving at a speed of 4.0 ft/min, will
transport the products between workstations. Because of the variability in the
time required to perform the assembly operations, it has been determined that
the tolerance time should be equal to 1.5 times the cycle time of the line.
(i) Determine the ideal number of workstations on the line.
(ii) Use the ranked positional weights method to balance the line.
(iii) Compute the balance delay for your solution in part (ii). [16]

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 Code No: RT41039 R13 Set No. 1

5. a) Explain the importance of automated work-in-process storage systems. [6]

b) Discuss the automated Storage/Retrieval Systems (AS/RS) controls, and the
special features and applications of AS/RS. [10]

6. a) What is adaptive control, and what are the major functions of adaptive control? [8]
b) Discuss the effect of various constraints such as cutting force, temperature,
vibration, and acoustic emission on adaptive control. [8]

7. a) Describe experimental procedure for machine vision. [8]

b) List some of the applications of CMM. [8]

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Code No: RT41039 R13 Set No. 2
IV B.Tech I Semester Regular/Supplementary Examinations, October/November - 2017
AUTOMATION IN MANUFACTURING
(Mechanical Engineering)
Time: 3 hours Max. Marks: 70
Question paper consists of Part-A and Part-B
Answer ALL sub questions from Part-A
Answer any THREE questions from Part-B
*****
PART–A (22 Marks)
1. a) What are the basic components of automated systems? [4]
b) Define transfer lines. [4]
c) Why storage buffers are used in automated production lines? [4]
d) List two applications of cranes and hoists. [4]
e) Name the different types of adaptive control systems. [3]
f) List out the various components of CMM [3]

PART–B (3x16 = 48 Marks)

2. a) Summarize feeding devices and tool changing devices. [8]
b) Discuss some of the reasons used to justify automation system. [8]

3. a) Make use of the given data and compute, a) Production rate b) Line efficiency
and c) Cost per unit piece produced on the line. For a 20-station transfer line, it
will operate at a production rate of 50 pieces per hour at 100% efficiency,
probability of station breakdown per cycle is equal to p = 0.005
breakdowns/cycle for all stations. Average down time per line stop is 8 minutes.
Machining cost is Rs.3 per component. The line operates at a cost of Rs.75/hr.
One cutting tool per station lasts for 50 parts and average cost per tool is Rs.2 per
cutting edge. [8]
b) Why are continuous work transport systems uncommon on automated production
lines? [8]

4. a) Discuss the different types of assembly systems. [8]

b) Explain the other ways to improve line balancing in flexible assembly lines. [8]

5. a) Explain the role of AS/RS in material handling systems. [8]

b) With neat sketch explain about fork lift truck. [8]

6. a) What are the advantages of adaptive control systems? [8]

b) Explain a typical adaptive control machining system. [8]

7. a) Explain the functions of a machine vision system. [8]

b) Explain any three CMM mechanical configurations. [8]

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 Code No: RT41039 R13 Set No. 3
IV B.Tech I Semester Regular/Supplementary Examinations, October/November - 2017
AUTOMATION IN MANUFACTURING
(Mechanical Engineering)
Time: 3 hours Max. Marks: 70
Question paper consists of Part-A and Part-B
Answer ALL sub questions from Part-A
Answer any THREE questions from Part-B
*****
PART–A (22 Marks)
1. a) Define automation. [3]
b) Distinguish between upper bound and lower bound approach. [4]
c) List out the advantages of kilbridge wester method. [3]
d) List three major categories of work transport systems in production lines. [4]
e) What is adaptive control optimization? [4]
f) What are the functions of machine vision? [4]

PART–B (3x16 = 48 Marks)

2. a) Distinguish between automated production system and CIM. [6]
b) Define automated machine tool? Classify actuators. What is the difference
between hydraulic and pneumatic actuators? [10]

3. a) Explain the three general methods of transporting the work pieces on automated
flow lines. [8]
b) An eight station rotary indexing machine operates with an ideal cycle time of 20
sec. The frequency of line stop occurrences is 0.06 stop / cycle on the average.
When a stop occurs it takes an average of 3 min to make repairs. Determine the
following: (i) Average production time (ii) Line efficiency (iii) Proportion of
downtime (iv) Average production rate. [8]

4. a) Explain any one method of line balancing with an example. [8]

b) Write short note on flexible assembly lines. [8]

5. a) An overhead trolley conveyor is configured as a continuous closed loop. It has a

delivery loop length of 75 m and return loop length 60 m. Each hook on the
conveyor can hold one part, and the hooks are separated by 4.5 m. The speed of
the conveyor is 40m/min. Determine the total number of parts in the conveyor
system, and the parts flow rate. [8]
b) Discuss the different types of AGV’s and their applications. [8]

6. Draw & Explain the block diagram of an Adaptive Control optimization system
for milling process. [16]

7. a) Summarize Machine vision applications in manufacturing. [8]

b) What are the various methods of automated inspection? Explain. [8]

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 Code No: RT41039 R13 Set No. 4
IV B.Tech I Semester Regular/Supplementary Examinations, October/November - 2017
AUTOMATION IN MANUFACTURING
(Mechanical Engineering)
Time: 3 hours Max. Marks: 70
Question paper consists of Part-A and Part-B
Answer ALL sub questions from Part-A
Answer any THREE questions from Part-B
*****
PART–A (22 Marks)
1. a) Write are the Benefits of industrial automation? [4]
b) What is a buffer storage? [3]
c) What is the importance of line balancing? [4]
d) Define material handling. [4]
e) Where to use adaptive control systems. [4]
f) What are the components of CMM? [3]

PART–B (3x16 = 48 Marks)

2. a) Explain the different types of production automation. Show, by suitable graph,
three types of production automation as a function of production volume and
product variety. [8]
b) Write about hopper, feed track and parts feeder. [8]

3. a) Explain the two principal reasons for the use of buffer storage zones. Show by
means of a diagram the case of two processing lines separated by a storage
buffer. [8]
b) Draw the neat sketches of any two transfer mechanisms and discuss briefly. [8]

4. A proposal has been submitted to replace a group of assembly workers, each

working individually, with an assembly line. The following table gives the
individual work elements.
Element Tc(min) Immediate predecessors
1 1.0 -
2 0.5 -
3 0.8 1,2
4 0.63 2
5 1.2 3
6 0.2 3,4
7 0.5 4
8 1.5 5,6,7

The demand rate for this job is 1600 units/week (assume 40 h/week) and the
current number of operators required to meet this demand is eight using the
individual manual workers.

(a) Construct the precedence diagram from the data provided on work elements.
(b) Use the largest-candidate rule to assign work elements to stations. What is
the balance delay for the solution? [16]

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Code No: RT41039 R13 Set No. 4

5. a) Discuss the design of material handling systems. [8]

b) Describe briefly traffic control patterns used in AGVs traffic management. [8]

6. a) What is the role of adaptive control in industry? [8]

b) Draw the block diagram of Adaptive Control with Constraint system for turning
operation. [8]

Explain the following inspection techniques:

7. (i) Electrical field technique
(ii) Radiation technique
(iii) Ultrasonic inspection technique [16]

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